Volvo All Models Installation Guide

Before Installation

Record the GPS ID

The installation technician must record which GPS unit is being installed in each vehicle before any Zonar equipment is installed.

Find the GPSID (S/N) number on the back of the unit. This number may be 7 or 8 digits long.

Record the asset (vehicle name) and the GPS being installed—this is important in order for the Zonar data to attach to the correct asset.

The following is an example of how to record this information on an Asset sheet:

ASSET

GPS ID

Truck 12345

8xxxxx1

Tractor 54563

11xxxxx2

Service Truck 5432

18xxxxx3

Set Up the Zonar Inspection Tags

Skip this section if electronic inspections (EVIR) will not be used for the vehicle receiving installation.

Vehicle Tags

Clean the surface area of the asset with isopropyl alcohol or brake cleaner before installing tags.

Remove the adhesive from the asset tag and record the Tag ID number on an asset sheet:

ASSET

GPS ID

ASSET TAG

Truck 12345

8xxxxx1

5387xxxx1

Tractor 54563

11xxxxx2

5387xxxx2

Service Truck 5432

18xxxxx3

5387xxxx3

See the Zonar Configuration Document for proper zone tag placement.

Install the zone tags in the proper areas for the corresponding vehicle inspection type. Depending on the configuration, not all zone tags may be used. Extra tags may be discarded.

Perform an electronic inspection to ensure correct tag placement.

Trailer Tags

Trailer/Dolly Tags are considered “Extended Asset” tags and may be black or marigold colored. They ship in sets of two (2) or three (3) tags with the name “Ext. Asset” on the back. These tags include both a 9-digit asset number and a zone number 01-03.

Required: Add the trailer to Ground Traffic Control (GTC) like other assets but with the TRAILER asset type. A GPS ID is not required for trailers unless one has been installed.

If a trailer is not created in the system but is used when doing inspections, this can cause inspections to fail. See our online support regarding Failed Inspections for guidance on correcting these.

Operator/Driver Card:

Nine (9) digits

Specific to driver

Zone Tags:

Numbered 01-11

Specific to location on vehicle

Asset Tags:

Nine (9) digits

Specific to vehicle

GPS & Cable Overview

Zonar Installation Kit

PART DESCRIPTION

PART NUMBERS

PHOTO

V3 GPS Unit

10079

J1939 Backbone Cable

81517

Y-Splitter Adapter

80082

Terminating Resistor

80083

Backbone Extension Cable

81524

Do not install Zonar devices or any excess cabling inside fuse panels, fuse boxes, or in any other location where the device or cabling (particularly unused cable ends/connections) might come into contact with energized circuits. Secure all excess cable lengths, cable runs, and unused cable connections/cable ends so that they cannot move or become loose over the lifetime of the installation.

Backbone Cable - GPS Unit Connections

10-pin connector – provides engine data to GPS

4-pin connector – provides power to GPS

Do not plug these cables into the GPS unit at this time.

Backbone Cable - Vehicle Connections

Ground Wire

Constant Power Wire – must receive 8-30 volts regardless of engine state

J1939 Connector (Yellow & Green)

J1708 Connector (Orange & Blue) – Not required for this install

Y-Splitter & Terminating Resistor

IMPORTANT: For backbone cable compatibility with the vehicle you are installing on, you must use the Y- Splitter & Terminating Resistor.

Vehicle J1939 Connection

Zonar Backbone Cable

Terminating Resistor

Backbone Extension Cable

The purpose of the Backbone Extension Cable is if the vehicle’s J1939 Terminating Resistor has a female end. If the installer is connecting to a male terminating resistor on the vehicle, this adapter is not needed.

Vehicle-Specific Installation

Fuse Panel

Find the fuse panel cover.

Remove the two screws behind the dash mounted cup holder.

Lift up to remove dash mounted cup holder.

Once the fuse panel cover has been removed the installer now has access to the following.

Vehicle J1939 Terminating Resistor

Constant Power Connections

Ground Connection

J1939 Connection

The J1939 terminating resistor will be connected as shown in the left photo.

Remove the resistor from the J1939 node as shown on the right.

Use needle-nose pliers to swap the guiding pin from the vehicle’s J1939 terminating resistor to the Zonar extension cable.

Connect the backbone extension cable to the vehicle backbone.

Connect the Zonar J1939 connector into the last remaining spot on the Y-Splitter.

Zonar Adapter

Zonar Provided Terminating Resistor

Vehicle’s J1939 Connection

Backbone Extension Cable if Vehicle J1939 Connection is Female

Zonar J1939 Connection

J1708 Connection

On older model vehicles, both the J1939 and J1708 connections are needed to get all required data.

Connect the Zonar J1708 connector into the vehicle’s junction block if available.

The J1708 wires may also be spliced directly into the wiring connected to the diagnostic port.

Orange - splice to pin F

Blue - splice to pin G

Constant Power

Locate a constant power source that measures 8-30 volts with engine off or on.

Zonar recommends attaching an Add-A-Fuse connector to the constant power wire. This will allow tapping directly into a fuse for ease of installation and maintenance. Connect the Add-A-Fuse as shown and connect it to a socket which provides constant power.

If not using the fuse panel, the constant power wire may be spliced directly into an appropriate power source.

Ground

Any place on the metal frame that is free of paint and rust may be used as an acceptable grounding point. Existing screws or self-tapping screws may be used to connect the ground wire.

Zonar recommends adding a ring terminal to the end of the ground wire for the most reliable connection.

The picture below shows both constant and ground spliced into the radio wiring.

GPS Unit Connections

If you are installing a Connect or 2020 tablet to this vehicle, skip this section.

On the GPS end of the harness, connect in the following order:

Connect the 10-pin (A) to the GPS unit (A).

Connect the 4-pin (B) to the GPS unit (B).

Confirm Install

Once the GPS unit is connected, check the LEDs on the left side of the unit. They should display the following sequence after everything is connected:

Datalink 1:

Flashing Green (J1708 Connected) or Red (J1708 Not Connected)

Datalink 2:

Flashing Green (J1939 Connected) or Red (J1939 Not Connected)

Cellular:

Flashing Green, turning solid Greenafter 1-2 minutes

GPS:

Flashing Orange, turning solid Orange after 2-3 minutes

Status:

Flashing Green with engine off, solid Green with engine running

Tablet Installation

Zonar Tablet Kit

Skip this section if you are not installing a tablet. Installation steps are the same for a 2020 tablet.

PART DESCRIPTION

PART NUMBERS

PHOTO

Zonar Connect Tablet

(or 2020 Tablet)

20081

(or 20067)

Connect Dock Ver 2

(or 2020 Dock)

20117

(or 20063)

Connect/2020 Power Serial Cable

20062

Connect/2020 Ram Mount, Mounting Bracket

20059

Ram Mount Screws

20079

Connect Power Serial Cable

The Connect tablet cable is responsible for communication between the GPS unit and the Connect dock. There are two ends to the cable--the dock end (#5) and the GPS unit end (#1-4).

Connects to the male 4-pin on the truck harness.

Connect to the 4-pin port on the GPS unit.

Not currently used.

Connect to the 8-pin port on the GPS unit.

Connect to the tablet dock.

Tablet Dock

Connect the 14-pin connector on the tablet cable to the back of the dock as shown to the left.

Mounting the Dock

The diagram to the left shows examples of ideal mounting locations. Mounting locations may vary based on the type of vehicle or driver requirements.

Attach RAM mount to a location visible and accessible to the driver.

Use backing plate to secure mount.

Once mounting is securely installed, dock the tablet.

Connecting Tablet to GPS Unit

Follow the diagram to the left to correctly connect the tablet cable to the GPS unit.

10-pin from backbone cable

8-pin from tablet cable

4-pin from tablet cable

4-pin from backbone cable connects to the female 4-pin on tablet cable

Confirm Install

Check the GPS lights according to the Confirm Install table above. The following may be used to confirm that the tablet is correctly connected as well:

Power on the tablet.

On the Driver Login screen, swipe down from the top right.

Tap SETTINGS from the sub menu that is displayed.

Tap Zonar Settings from the DEVICE section.

Tap Run Device Diagnostics from the DIAGNOSTICS section.

The Diagnostics dashboard is displayed. Check to see that the GPS and GSM icons are green. This means that the tablet and GPS unit are communicating properly, and they are getting the needed cellular and GPS information.

Further Assistance

If you still require assistance after using this installation document, contact Zonar Customer Care: